Air Conditioning: Other Volkswagen Golf Mk7

HANDLING REFRIGERANT SAFETY PRECAUTIONS

Note. All safety precautions regarding performing repairs on vehicles with air conditioning and working with refrigerant. Refer to A/C SYSTEM AND REFRIGERANT R134A, SAFETY PRECAUTIONS . Information on tools for repairs in vehicles with climate control system can be found in SPECIAL TOOLS If there are unpleasant odors coming from the evaporator, clean it with the Ultrasound A/C Cleaner VAS 6189A or with a pressure cup gun V.A.G 1538. The operating instructions are provided with the tools.

Note. Numerous procedures varying in their application and effect are available on the market for cleaning the evaporator. Currently, Volkswagen approves using Ultrasound A/C Cleaner -VAS 6189A- or pressure cup gun -V.A.G 1538- and a spray nozzle to clean the evaporator. Should Volkswagen test and approve other methods, the information will be published in Refrigerant R134a Servicing.

OIL DISTRIBUTION

The oil, which is located in the sump of the A/C compressor before initially switching on the air conditioner system, is distributed through the refrigerant circuit as follows

1. A/C compressor approximately 50%
2. Condenser approximately 10%
3. Suction hose approximately 10%
4. Evaporator approximately 20%
5. Fluid reservoir approximately 10%

REPAIRING VEHICLES EQUIPPED WITH A/C AND HANDLING REFRIGERANTS

Note. Information for repairing vehicles with air conditioning and working with refrigerant, refer to A/C SYSTEM, REPAIR INFORMATION . Information for special tools and equipment when repairing vehicles with air conditioning, refer to SPECIAL TOOLS . If there are unpleasant odors coming from the evaporator, clean it with the Ultrasonic HVAC Cleaning System VAS 6189A or with a pressure cup gun V.A.G 1538. The operating instructions are provided with the tools. Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS

1. Information regarding performing repairs on vehicles with air conditioning and working with refrigerant. Refer to «A/C SYSTEM, REPAIR INFORMATION»(ref-480987-S19955573942012061900000) .
2. Information on tools for repairs in vehicles with climate control system. Refer to «SPECIAL TOOLS»(ref-480983-S31245405742012061900000) .
3. Under certain conditions, the dryer cartridge should no longer be replaced each time the refrigerant circuit is opened.
4. The procedure for flushing with refrigerant R134a is described in «REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A»(ref-480987-S08627795062012061900000)

Note. Flush the refrigerant circuit with R134a refrigerant under the following conditions: In the event of dirt or other contamination in the refrigerant circuit. If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure build-up due to moisture in refrigerant circuit). If refrigerant circuit has been left open for longer than normal (for example, following an accident). If pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture In the event of doubt about the amount of refrigerant oil in the circuit. The A/C compressor had to be replaced on account of internal damage (for example, noise or no output).

HIGH VOLTAGE SYSTEM GENERAL WARNINGS

Note. "High voltage technician", and "high voltage expert" should speak with the designated importer, about any questions or unclear matters before beginning any and all work with the high voltage system.

Disable the high voltage system.

START/STOP SYSTEM

Read safety precautions when working on vehicles with start/stop system, refer to START/STOP SYSTEM SAFETY PRECAUTIONS

If the vehicle has a Start/Stop System, then perform the following termination conditions to deactivate the system

1. Use the Start/Stop button to switch off the Start/Stop System.
2. The battery state of charge does not make it possible to start the engine again (start voltage prediction).
3. The defrost function is active.
4. The heated front windshield is active.
5. The selected temperature deviates more than 8 °C from the actual temperature inside the vehicle.
6. The engine RPM exceeds 1, 200 RPM.
7. The generator -C- is faulty, for example, the ribbed belt is torn.
8. The coolant temperature is not in the specified range of 25 °C to 100 °C.
9. Increasing the blower speed by more than 4 steps.

Further information

1. Refer to the «START/STOP SYSTEM SAFETY PRECAUTIONS»(ref-480983-S21055687202012061900000)

START/STOP SYSTEM SAFETY PRECAUTIONS

A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC

Note. An indicator lamp inside the controls indicates when the selected function is on. In addition to this, whenever a button or a control is selected, the function will briefly appear in the radio or radio/navigation system display. If the lamp in the AC button does not come after the button is pushed, there may be a fault in the control module. Check the DTC memory with the Vehicle Diagnosis, Testing and Information System VAS 5051B (or succeeding model). If the fault entry A/C compressor first start not performed is present, then is it necessary to perform a basic setting and an adaptation A/C compressor first start in Guided Fault Finding. To change from °C and °F in the radio or radio/navigation system display, go to the main menu in the instrument cluster. Use the switch on the windshield wiper lever (or multifunction steering wheel) to call up the main menu. Select settings, units and temperature. Pressing the button AUTO will reverse all settings which deviate from the automatic operation. Deviations from automatic operation, refer to the respective operating instructions. When the OFF button is activated, the Climatronic does not work. There is no heating or ventilation. When the OFF button is deactivated, the Climatronic works. When the AC button is activated, the A/C compressor is switched on. The heating and ventilation operation continues to be controlled electronically. If the AC button is deactivated, the A/C compressor is set to almost no delivery. The heating and ventilation operation continues to be controlled electronically. Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Note. Information for repairing vehicles with air conditioning and working with refrigerant, refer to A/C SYSTEM, REPAIR INFORMATION . Information for special tools and equipment when repairing vehicles with air conditioning, refer to SPECIAL TOOLS . Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Note. Flush the refrigerant circuit with R134a refrigerant under the following conditions: In the event of dirt or other contamination in the refrigerant circuit. If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure buildup due to moisture in refrigerant circuit). If refrigerant circuit has been left open for longer than normal (e.g. following an accident). If pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture In the event of doubt about the amount of refrigerant oil in the circuit. The A/C compressor had to be replaced on account of internal damage (e.g. noise or no output).

The procedure for flushing with R134a refrigerant is described in REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A .

Tools and Equipment

Information for special tools and equipment when repairing vehicles with air conditioning, refer to SPECIAL TOOLS .

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1783
2. A/C service station VAS 6007A or succeeding model.
3. "Ratchet Insert 1/4" VAS 6234
4. Socket insert T10364

EXPANSION VALVE FUNCTION

1. The expansion valve atomizes the streaming refrigerant and controls the flow quantity so that the vapor is gaseous only at the evaporator outlet, depending on the heat transmission.

REFRIGERANT CIRCUIT COMPONENTS

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Hose clamps up to 40 mm diameter 3093
3. drip tray for shop crane VAS 6208
4. A/C service station VAS 6007A or succeeding model.

Note. Refrigerant must be extracted before hand using VAS 6007A. The previously used service stations can still be used. To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs. The color coding of O-rings for the R134a refrigerant circuits has been discontinued. Colored and black O-rings are used. Under certain conditions, the reservoir and the dryer/dryer bag does not need to be replaced each time the refrigerant circuit is opened. Refer to NOT REPLACING RESERVOIR/FLUID RESERVOIR OR DRYER BAG/CARTRIDGE, CONDITIONS . Information for repairing vehicles with air conditioning and working with refrigerant, refer to A/C SYSTEM, REPAIR INFORMATION . Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Scheme 57

1. Reservoir with Dryer or Dryer Bag NOTE: Under certain conditions, the reservoir and the dryer/dryer bag does not need to be replaced each time the refrigerant circuit is opened. Refer to «NOT REPLACING RESERVOIR/FLUID RESERVOIR OR DRYER BAG/CARTRIDGE, CONDITIONS»(ref-480987-S33733117112012061900000) . Condenser manufactured by Showa: Reservoir with dryer, removing and installing, refer to «FLUID RESERVOIR WITH DRYER»(ref-480983-S34624433632012061900000) . Condenser manufactured by Modine: Dryer bag, removing and installing, refer to «DRYER CARTRIDGE»(ref-480983-S35245455892012061900000) .
2. A/C Compressor Delphi designation: 6CVC 140 Sanden designation: PXE16 Denso designation: 6SEU14C; 7SEU17C Pay attention to notes for installing A/C compressor. Refer to «A/C COMPRESSOR, INSTALLATION INFORMATION»(ref-480983-S40485403332012061900000) . Removing and installing, refer to «A/C COMPRESSOR»(ref-480983-S15035039222012061900000) .
3. Condenser Removing and installing, refer to «CONDENSER»(ref-480983-S19036233182012061900000) .
4. High Pressure Sensor -G65- Removing and installing, refer to «HIGH PRESSURE SENSOR, GASOLINE»(ref-480983-S00500704802012061900000) or «HIGH PRESSURE SENSOR, COMMON RAIL»(ref-480983-S39130057442012061900000) for diesel.
5. Nuts 6 Nm
6. Bracket
7. Evacuating and Charging Valve High pressure side. Environmentally hazardous draining of refrigerant is an offense punishable by law. Removing and installing, refer to «EVACUATING AND CHARGING VALVE, LOW AND HIGH PRESSURE SIDES»(ref-480983-S20416075202012061900000) . Capacities, refer to «CAPACITIES»(ref-480983-S19303528732012061900000) .
8. Bolt 3.5 Nm
9. Retainer
10. Evacuating and Charging Valve Low pressure side Environmentally hazardous draining of refrigerant is an offense punishable by law. Removing and installing, refer to «EVACUATING AND CHARGING VALVE, LOW AND HIGH PRESSURE SIDES»(ref-480983-S20416075202012061900000) . Capacities, refer to «CAPACITIES»(ref-480983-S19303528732012061900000) .
11. Expansion Valve Function and removal, refer to «EXPANSION VALVE»(ref-480983-S18882537642012061900000) .
12. Bracket
13. Nut 20 Nm
14. Bracket
15. Screw 3.5 Nm

A/C CONTROL UNIT PIN ASSIGNMENT

1. «PIN ASSIGNMENT, CLIMATIC CONTROL UNIT, THROUGH MAY 27, 2011»(ref-480983-S16394646332012061900000)
2. «PIN ASSIGNMENT, ELECTRICAL MANUAL CLIMATE CONTROL UNIT, FROM MAY 29, 2011»(ref-480983-S20788542352012061900000)
3. «PIN ASSIGNMENT, CLIMATRONIC CONTROL UNIT»(ref-480983-S02355372662012061900000)

PIN ASSIGNMENT, CLIMATIC CONTROL UNIT, THROUGH MAY 27, 2011

Special tools and workshop equipment required

1. Test Box -V.A.G 1598/42
2. Test Adapter -V.A.G 1598/47
3. Template -1598/47-2

Scheme 58

20-pin Harness Connector, in Wiring Diagram T20c

3 - Center Outlet Temperature Sensor -G191

5 - High Pressure Sensor -G65

7 - CAN Low

8 - CAN High

12 - Right seat heater (optional)

13 - Seat heating (option)

15 - Terminal 75 seat heater (optional)

16 - A/C Compressor Regulator Valve -N280

18 - Center outlet temperature sensor -G191- ground

19 - Terminal 30A

20 - Terminal 31

16-pin Harness Connector, in Wiring Diagram T16e

1 - Temperature regulator door motor -V68-, warm

2 - Evaporator temperature sensor -G308- or Evaporator vent temperature sensor -G263

3 - Air distribution door motor position sensor -G645

4 - Footwell outlet temperature sensor -G192

5 - Temperature regulator door motor position sensor -G92

7 - + 5 V for Temperature regulator door motor position sensor - G92

8 - Ground for the Front air distribution door motor position sensor -G92-, the Footwell vent temperature sensor -G192- ; the air distribution door motor position sensor -G645- and the evaporator temperature sensor -G308- or evaporator vent temperature sensor -G263

9 - Recirculation door motor -V113-, open

10 - Recirculation door motor -V113-, close

11 - Temperature regulator door motor -V68-, cold

12 - Air distribution door motor -V428-, open

13 - Air distribution door motor -V428-, closed

5-pin Harness Connector, in Wiring Diagram T5

1 - 3rd Blower Speed

2 - 2nd Blower Speed

3 - 1st Blower Speed

4 - 4th Blower Speed

5 - Terminal X

PIN ASSIGNMENT, ELECTRICAL MANUAL CLIMATE CONTROL UNIT, FROM MAY 29, 2011

Special tools and workshop equipment required

1. Basic Test Box -V.A.G 1598/14
2. Test Adapter -V.A.G 1598/47
3. Template -V.A.G 1598/47-2

Scheme 59

5-pin Harness Connector -A- in Wiring Diagram T5

1 - 3rd Blower Speed

2 - 2nd Blower Speed

3 - 1st Blower Speed

4 - 4th Blower Speed

5 - Terminal X

16-pin Harness Connector -B- in Wiring Diagram T16e

1 - Temperature regulator door motor -V68-, warm

2 - Evaporator temperature sensor -G308

3 - Air distribution door motor position sensor -G645

5 - Temperature regulator door motor position sensor -G92

7 - +5V

8 - Ground signal

9 - Recirculation door motor -V113- set to open

10 - Recirculation door motor -V113- set to closed

11 - Temperature door motor -V68- - set to cold

12 - Air distribution door motor -V428-, set to position 1

13 - Air distribution door motor -V428-, set to position 2

PIN ASSIGNMENT, CLIMATRONIC CONTROL UNIT

Special tools and workshop equipment required

1. Test Box -V.A.G 1598/42
2. Test Adapter -V.A.G 1598/47
3. Template -1598/47-2

Scheme 60

20-pin Harness Connector -A-, in Wiring Diagram T20c

1 - Sunlight photo sensor 2 -G134- or Sunlight photo sensor - G107-, signal

2

3 - Sunlight photo sensor 2 -G134- or Sunlight photo sensor - G107-, signal

5 - High speed CAN Bus

6 - Low speed CAN Bus

9 - + 5V for Sunlight photo sensor 2 -G134- or Sunlight photo sensor -G107

10 - Heated driver seat adjuster -E94- (optional)

11 - Heated front passenger seat adjuster -E95- (optional)

12 - Terminal 75 (optional)

13 - Left vent temperature sensor -G150- (from January 2004)

14 - Right vent temperature sensor -G151- (from January 2004)

16 - Terminal 30a/ terminal 15

17 - Signal Ground (GND) for Sunlight photo sensor -G107-, Sunlight photo sensor 2 -G134-, Left vent temperature sensor - G150- and Right vent temperature sensor -G151-.

18 - A/C compressor regulator valve -N280

19 - Terminal 31

20 - Terminal 30a/ terminal 15

16-pin Connector, -B-, In Wiring Diagram T16c9 - + 5V for Sunlight photo sensor 2 -G134- or Sunlight photo sensor -G107

1 - + 5V for motors

2 - Left temperature door potentiometer/actuator -G220

3 - Right temperature door potentiometer/actuator -G221

4 - Defroster door motor position sensor -G135

5 - Front air distribution door motor position sensor -G642

6 - Recirculation door motor position sensor -G143- (through December 2003) temperature regulator door motor position sensor -G92- (from January 2004)

7 - Back pressure door motor position sensor -G113

8 - Left footwell vent temperature sensor -G261

9 - Right footwell vent temperature sensor -G262

10 - Fresh air intake duct temperature sensor -G89- (through September 2005)

11 - Evaporator temperature sensor -G308- or Evaporator vent temperature sensor -G263

14 - Signal Ground (GND) potentiometer

15 - Left vent temperature sensor -G150- (through December 2003)

16 - Right vent temperature sensor -G151- (through December 2003)

16-pin Connector, -C-, In Wiring Diagram T16d

1 - Left temperature door motor -V158-, cold

2 - Left temperature door motor -V158-, warm

3 - Defroster door motor -V107-, closed

4 - Defroster door motor -V107-, open

5 - Front air distribution door motor -V426-, upper body outlet

6 - Front air distribution door motor -V426-, footwell

7 - Fresh/recirculation air door motor -V154- air recirculation activation (through December 2003) air recirculation door motor - V113- (from January 2004); motor function deleted (from June 2007) by the fresh air/recirculating air/back pressure door motor -V425- and mount.

8 - Fresh/recirculation air door motor -V154- fresh air activation (through December 2003) air recirculation door motor -V113- (from January 2004)

9 - Airflow door motor -V71-, open (through May 2007)

10 - Airflow door motor -V71-, closed (until May 2007)

11 - Right temperature door motor -V159-, cold

12 - Right temperature door motor -V159-, warm

15 - Fresh air blower control module -J126

16 - Control module for fresh air blower -J126-, signal

Scheme 61

1. Temperature Regulator Door Motor -V68- Checking: use the vehicle diagnostic tester Removing and installing, refer to «TEMPERATURE REGULATOR DOOR MOTOR - V68»(ref-480983-S24050137562012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.
2. Air Distribution Door Motor -V428- With Air Distribution Door Motor Position Sensor - G645- Checking: use the vehicle diagnostic tester Removing and installing, refer to «AIR DISTRIBUTION DOOR MOTOR -V428»(ref-480983-S13126837302012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.
3. Recirculation Door Motor - V1 Checking: use the vehicle diagnostic tester Removing and installing, refer to «RECIRCULATION DOOR MOTOR -V113»(ref-480983-S15468194692012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.

Scheme 62

1. Left Temperature Door Motor -V158- Checking: use the vehicle diagnostic tester Removing and installing, refer to «LEFT TEMPERATURE DOOR MOTOR -V158»(ref-480983-S08716574132012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.
2. Defroster Door Motor - V107- Checking: use the vehicle diagnostic tester Removing and installing, refer to «DEFROSTER DOOR MOTOR -V107»(ref-480983-S31560155662012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.
3. Front Air Distribution Door Motor -V426- With Front Air Distribution Door Motor Position Sensor -G642- Checking: use the vehicle diagnostic tester Removing and installing, refer to «FRONT AIR DISTRIBUTION DOOR MOTOR -V426- AND POSITION SENSOR -G642»(ref-480983-S03964990272012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.
4. Fresh Air/Recirculating Air/Back Pressure Door Motor -V425- Checking: use the vehicle diagnostic tester Removing and installing, refer to «FRESH AIR/RECIRCULATING AIR/BACK PRESSURE DOOR MOTOR -V425»(ref-480983-S25437344292012061900000) Replacing: initiate the basic setting using the vehicle diagnostic tester.
5. Right Temperature Door Motor -V159- Checking: use the vehicle diagnostic tester Removing and installing, refer to «RIGHT TEMPERATURE DOOR MOTOR -V159»(ref-480983-S05713413972012061900000) . Replacing: initiate the basic setting using the vehicle diagnostic tester.

AIR QUALITY SENSOR -G238

1. The air quality sensor -G238- detects pollutants in the ambient air (mostly gasoline and/or diesel fumes).
2. The climatronic control module -J255- evaluates signal from the air quality sensor. The A/C system is activated depending on the strength and type of heavily polluted air.

At an outside temperature above approximately +2 °C, the recirculating air mode is switched on when there is only a slight increase in pollutants in the ambient air.

At an outside temperature between approximately +2 °C and approximately -8 °C, the change over to recirculating air mode only occurs at a sharp increase of pollutant concentration, during which the compressor is switched on simultaneously.

At an outside temperature less than approximately -5 °C, the system still only changes to recirculation mode when there is a strong increase in the level of pollutants. However, it only switches on for approximately 15 seconds and the A/C compressor does not switch on. If the concentration decreases, the air conditioner switches to the fresh air mode.

1. Automatic recirculating air mode can be switched off at any time. If the function is active, the A/C compressor is switched on with a request for automatic recirculating air mode and also when the outside air temperature is below +2 °C. If the temperature is below -5 °C, it is not possible to use the A/C compressor.
2. If the vehicles has automatic recirculating air mode, the A/C compressor can also be manually switched on when the temperature is approximately -5 °C.
3. To ensure that the A/C does not operate constantly in the recirculating air mode in areas with a consistently higher pollution, the sensor is self learning (it adjusts its sensitivity to the environmental conditions).
4. If outside air pollution load remains high for longer period of time, the sensor starts to adapt itself to the changing environmental condition through an adaptation program (learning program), the air recirculation request in evenly polluted ambient air is therefore generally shorter than 12 minutes. If a succession of peaks in the polluted air is detected, the air conditioning system can operate over a longer period of time in recirculated air mode.
5. A certain amount of time is required for repositioning of the air conditioning system doors. In the event that a sudden increase in pollutants is encountered (e.g. when driving through a diesel exhaust cloud) gaseous pollutants can be taken in with the fresh air into the passenger compartment until the door can be closed. For this reason, a dust and pollen filter is installed with a charcoal layer. A filter that is saturated with pollutants is no longer effective and needs to be replaced.
6. In order to avoid frequent shifting of the recirculated air/fresh air door, a slight increase of pollutants in the ambient air will not allow for immediate shifting (the sensor does not send a request to climatronic control module). The filtering of the charcoal insert in the dust and pollen filter will be sufficient.
7. In order to avoid frequent shifting of the recirculating air/fresh air door, the requirement from the sensor for Automatic air recirculation mode remains for at least 25 seconds (minimum duration period), even if the pollutant concentration is so far reduced that recirculating air mode is no longer necessary.
8. If the A/C compressor is switched off (the AC button is off), then the climatronic control module limits the automatic recirculating air mode to approximately 15 seconds to prevent the windows from fogging up.
9. So that fogged windows are cleared as quickly as possible, the climatronic control module does not permit recirculated air operation during the Defrost operating mode.
10. After the ignition is switched on, the air quality sensor requires approximately 30 seconds to be operational (warm-up time). During this time there is no requirement from the sensor to climatronic control module for Automatic recirculated air mode.
11. The air quality sensor contains a highly sensitive electronic component which can be damaged if it comes in direct contact with solvents, fuels or chemicals. For this reason, do not install sensors that may have come into contact with these substances.

MULTI-PIN CONNECTORS ON BACK OF CLIMATIC HEATING AND A/C CONTROL, PIN ASSIGNMENT

Special tools and workshop equipment required

1. Test box V.A.G 1598/42
2. Adapter cable V.A.G 1598/47
3. Template 1598/47-2

20-Pin Harness Connector, in Wiring Diagram T20c

3 - Center Outlet Temperature Sensor -G191

5 - High Pressure Sensor -G65

7 - CAN Low

8 - CAN High

12 - Right seat heater (optional)

13 - Seat heating (option)

15 - Terminal 75 seat heater (optional)

16 - A/C Compressor Regulator Valve -N280

18 - Center outlet temperature sensor -G191- ground

19 - Terminal 30A

20 - Terminal 31

16-Pin Harness Connector, in Wiring Diagram T16e

1 - Temperature Regulator Door Motor -V68-, warm

2 - Evaporator Temperature Sensor -G308- or Evaporator Vent Temperature Sensor -G263

3 - Air distribution door motor position sensor -G645

4 - Footwell Outlet Temperature Sensor -G192

5 - Temperature Regulator Door Motor Position Sensor -G92

7 - + 5 V for Temperature Regulator Door Motor Position Sensor -G92

8 - Ground for the front air distribution flap motor position sensor -G92-, the footwell vent temperature sensor -G192- ; the air distribution door motor position sensor -G645- and the evaporator temperature sensor -G308- or evaporator vent temperature sensor -G263

9 - Recirculation Door Motor -V113-, open

10 - Recirculation Door Motor -V113-, close

11 - Temperature Regulator Door Motor -V68-, cold

12 - Air distribution flap motor -V428-, open

13 - Air distribution flap motor -V428-, closed

5-Pin Harness Connector, in Wiring Diagram T5

1 - 3rd blower speed

2 - 2nd blower speed

3 - 1st blower speed

4 - 4th blower speed

5 - Terminal X

MULTI-PIN CONNECTORS A, B AND C ON REAR OF CLIMATRONIC CONTROL MODULE, PIN ASSIGNMENT

Special tools and workshop equipment required

1. Test box V.A.G 1598/42
2. Adapter cable V.A.G 1598/47
3. Template 1598/47-2

20-Pin Harness Connector, in Wiring Diagram T20c

Scheme 63

1 - Sunlight Photo Sensor 2 -G134- or Sunlight Photo Sensor -G107-, signal

2 - High Pressure Sensor -G65

3 - Sunlight Photo Sensor 2 -G134- or Sunlight Photo Sensor -G107-, signal

4 - Air Quality Sensor -G238

5 - CAN High

6 - CAN Low

7 - Indirect ventilation door control motor -V213

8 - Indirect ventilation door control motor -V213

9 - + 5V for sunlight photo sensor 2 -G134- or sunlight photo sensor -G107

10 - Heated driver seat adjuster -E94- (optional)

11 - Heated front passenger seat adjuster -E95- (optional)

12 - Terminal 75 (optional)

13 - Outlet temperature sensor -G150

14 - Right Vent Temperature Sensor -G151

15 - Indirect ventilation flap motor position sensor -G330

16 - Terminal 30a/without auxiliary heater terminal 15

17 - Signal ground for sunlight photo sensor -G107-, sunlight photo sensor 2 -G134-, left vent temperature sensor -G150-, right vent temperature sensor -G151- and indirect ventilation flap motor -V213

18 - A/C Compressor Regulator Valve -N280

19 - Terminal 31

20 - Terminal 30a/without auxiliary heater terminal 15

16-Pin Harness Connector, in Wiring Diagram T16c

1 - + 5V for motors

2 - Temperature Regulator Door Motor Position Sensor -G220

3 - Right Temperature Door Potentiometer/Actuator -G221

4 - Defroster Door Motor Position Sensor -G135

5 - Front air distribution flap motor position sensor -G642

7 - Fresh air/recirculating air/back pressure flap motor position sensor -G644-.

8 - Footwell Outlet Temperature Sensor -G261

9 - Right Footwell Vent Temperature Sensor -G262

11 - Evaporator vent temperature sensor -G263- or evaporator temperature sensor -G308

14 - Signal ground (GND) potentiometer

16-Pin Harness Connector, in Wiring Diagram T16d

1 - Left Temperature Door Motor -V158-, cold

2 - Left Temperature Door Motor -V158-, warm

3 - Defroster Door Motor -V107-, closed

4 - Defroster Door Motor -V107-, open

5 - Front air distribution flap motor -V426-, upper body outlet

6 - Front air distribution flap motor -V426-, footwell

9 - Fresh air/recirculating air/back pressure flap motor -V425-, open

10 - Fresh air/recirculating air/back pressure flap motor -V425-, closed

11 - Right Temperature Door Motor -V159-, cold

12 - Right Temperature Door Motor -V159-, warm

15 - Fresh Air Blower Control Module -J126

16 - Control module for fresh air blower -J126-, signal

CLIMATRONIC CONTROL MODULE DISPLAY AND CONTROL HEAD AND CLIMATRONIC CONTROL MODULE FUNCTIONALITY

Note. An indicator lamp inside the controls indicates when the selected function is on. In addition to this, whenever a button or a control is selected, the function will briefly appear in the radio or radio/navigation system display. To change from °C and °F in the radio or radio/navigation system display, go to the main menu in the instrument cluster. Use the switch on the windshield wiper lever (or multifunction steering wheel) to call up the main menu. Select settings, units and temperature. Perform a basic setting and an adaptation A/C compressor first start either in Guided Fault Finding or Guided Functions when a new Climatronic control module display -E87- and a Climatronic control module -J255- are installed. Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

1. Windshield Defroster Button
2. Button - Upper Air Distribution
3. Button - Center Air Distribution
4. Interior Temperature Sensor
5. Button - Lower Air Distribution
6. Recirculating Air Mode or Automatic Recirculating Air Mode Button Press button for recirculating air function to prevent polluted air from entering interior. repeatedly pressing the recirculating air mode button activates the automatic recirculating air mode NOTE: Air quality sensor -G238- function, refer to «AIR QUALITY SENSOR FUNCTION»(ref-480983-S07265553372012061900000) .
7. Push Button for Rear Window Defroster
8. Right Side Interior Temperature Control
9. Right Seat Heating Button (Option)
10. Push Button AC Press the AC button to switch air conditioning on and off. When the light in the button is on, the air conditioner compressor is switched on.
11. Push Button DUAL If the indicator light in the button comes on, different temperatures can be set for left and right. If the button Dual is pressed and the indicator light goes out, the driver's side temperature control also controls the passenger's side.
12. Immediate Heating Button -E537- NOTE: On vehicles equipped with auxiliary heating.
13. Blower Regulator Changed blower speed by tapping.
14. A/C OFF Button Switching the Climatronic on and off.
15. Push Button AUTO By pressing the AUTO button, Climatronic maintains the selected vehicle interior temperature completely automatically. With this setting the vent air temperature, the blower speed and the air distribution are controlled automatically.
16. Interior Temperature Knob
17. Seat Heating Button (Option)

REFRIGERANT R134A

REFRIGERANT OIL

Note. The special refrigerant oil (for use with refrigerant circuits R134a only) is no longer obtainable on the refrigerant/machine oil market. Do not use refrigerant oil that was stored for long periods of time in open containers. This quantity of refrigerant oil is in a replacement A/C compressor and equates to the total capacity.

1. This quantity of refrigerant oil is in a replacement A/C compressor and equates to the total capacity.

Important Information

Refrigerant oil attracts moisture. Close any opened containers immediately after use to prevent moisture from entering.

Refrigerant oil, because of its chemical properties, must not be disposed of with engine oils or transmission oils.

Oil Distribution

The oil, which is located in the sump of the A/C compressor before initially switching on the air conditioner system, is distributed through the refrigerant circuit as follows

1. A/C compressor approximately 50 %
2. Condenser approximately 10 %
3. Suction hose approximately 10 %
4. Evaporator approximately 20 %
5. Fluid reservoir approximately 10 %

A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS

Special tools and workshop equipment required

1. Vehicle diagnosis, testing and information system VAS 5051B

Select Guided Fault Finding on the VAS 5051B (or newer model).

After all control modules have been interrogated

Press Go to button.

Select Function/component selection.

Select Body.

Heating, ventilation, air conditioning (Repair Group 01; 80 to 87).

Select 01 - On Board Diagnostic (OBD) capable systems.

Select Climatronic or Climatic.

Select Functions

Basic setting.

A/C compressor first start.

Check coolant output.

Read measured value block.

Coding.

AUXILIARY AIR HEATER HEATING ELEMENT - Z35-, CHECKING

Special tools and workshop equipment required

1. Vehicle Diagnostic Tester with inductive pickup 100A -VAS 5051B/7

Checking with Periphery

Auxiliary Air Heater Heating Element Periphery (load signal for generator terminal DF, Preheating Coolant, Low Heat Output Relay -J359-, Preheating Coolant, High Heat Output Relay -J360-, Intake Air Temperature (IAT) Sensor -G72-, Engine Coolant Temperature (ECT) Sensor -G62-) can be interrogated via the engine control module self diagnosis.

Checking

Test Conditions

1. Intake temperature less than 19° C (66 °F)
2. Coolant temperature less than 80° C (176 °F)
3. Passenger compartment temperature approximately 20° C (68 °F)
4. Battery voltage greater than 11 V
5. Alternator load not greater than 50% (terminal DF)
6. Engine speed greater than 450 RPM
7. Turn the interior temperature knob to maximum heating.

Test Sequence

1. Remove the knee airbag. Refer to Body Interior; 9 ; Removal and Installation.
2. Remove the driver footwell vent. Refer to «DRIVER SIDE FOOTWELL VENT»(ref-480983-S14599476512012061900000) .
3. Remove footwell trim.
4. Measure the current draw on the ground cable -arrow- using the Vehicle Diagnostic Tester and the trigger clamp 100A.

Scheme 64

Slight heat output approx. 30 A

Medium heat out approx. 60 A

Large heat output approx. 80 A

Scheme 65

Remove front passenger side footwell cover.

Note. It must be possible to connect the condensation water hose -1- to the connection on the heater/air conditioner without having any tension on it. The condensation water hose must fit securely to the condensation water drain connection on the tunnel.

PASSENGER COMPARTMENT FORCED AIR VENTILATION, CHECKING

1. The stale air escapes through the vent openings in the luggage compartment trim.
2. If the ventilation is to function properly, the ventilation openings must not be covered.
3. The ventilation frames are located in the rear side panels, behind the bumper.

The ventilation can be checked through the luggage compartment.

Depending on the vehicle equipment level, it may be necessary to remove additional components.

Remove the side trim panels inside the luggage compartment.

The sealing lips in the vent frame on both sides of the vehicle must move freely and close by themselves.

PRESSURE RELIEVE VALVE ON A/C COMPRESSOR, CHECKING

1. Function: protects refrigerant circuit against excessive pressure. - When working on the refrigerant circuit, note the information, refer to «REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS»(ref-480983-S33958756372012061900000) .

Checking check valve on A/C compressor (Denso)

Scheme 66

1. The pressure relief valve -arrow- has operated when refrigerant oil is found in the close vicinity.
2. In this case, vehicle must be taken to an A/C specialist workshop. Refer to «REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS»(ref-480983-S36966191182012061900000) .

A/C COMPRESSOR

Note. Perform Guided Fault Finding A/C compressor first start whenever a new A/C compressor is installed. Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Removing

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331/ (5 to 50 Nm)
2. A/C service station VAS 6007A or succeeding model.

Note. Flush the refrigerant circuit with R134a refrigerant under the following conditions: In the event of dirt or other contamination in the refrigerant circuit. If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure build-up due to moisture in refrigerant circuit). If refrigerant circuit has been left open for longer than normal (e.g. following an accident). If pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture. In the event of doubt about the amount of refrigerant oil in the circuit. The A/C compressor had to be replaced on account of internal damage (e.g. noise or no output). If only the auxiliary component bracket is being removed, it is not necessary to loosen the refrigerant lines on the A/C compressor. Attach the A/C compressor to the body with wire.

The procedure for flushing with R134a refrigerant, refer to REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A .

Information for repairing vehicles with air conditioning and working with refrigerant, refer to A/C SYSTEM, REPAIR INFORMATION .

Information for special tools and equipment when repairing vehicles with air conditioning, refer to SPECIAL TOOLS .

Extract refrigerant e.g. using VAS 6007A, only then open the refrigerant circuit. Observe notes. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Scheme 67

Remove noise insulation beneath engine. Refer to Description and Operation .

Note. The right front wheel housing liner must be removed, depending on the engine. Refer to Removal and Installation .

Remove the ribbed belt. Refer to RIBBED BELT or RIBBED BELT .

Remove the bolts -1- (22 ± 1 Nm) and disconnect the refrigerant lines from the A/C compressor.

Remove the bolts -2- (25 ± 2 Nm) and then remove the A/C compressor.

Installing

Tighten the bolts -1- to 22 ± 1 Nm and the bolts -2- to 25 ± 2 Nm.

Note. Perform Guided Fault Finding A/C compressor first start whenever a new A/C compressor is installed. Make sure alignment bushings -3- are seated correctly. Pay attention to notes for installing A/C compressor. Refer to A/C COMPRESSOR, INSTALLATION INFORMATION .

Note. Perform Guided Fault Finding "A/C compressor first start" whenever a new A/C compressor is installed.

Secure bolts -1- (22 +/- 1 Nm) and bolts -2- (25 +/- 2 Nm).

After installing a new A/C compressor or fresh refrigerant oil has been filled into compressor (for example after blowing through the A/C system), turn ribbed belt pulley of A/C compressor 10 rotations by hand before starting the engine. This prevents damage to the A/C compressor.

Start the engine only after assembling the refrigerant circuit.

Start engine with A/C compressor already turned off (indicator lamp button AC is off) and wait until the idle RPM as been attained.

Open the instrument panel vents.

Select the temperature setting "Lo" on the Climatronic A/C display control head -E87-.

Turn on the A/C compressor (indicator lamp button AC is lit) and let the engine idle for at least 5 minutes.

Note. The A/C compressor is always driven by the ribbed belt pulley (no A/C clutch). If the A/C compressor is blocked, the compressor shaft overload protection is activated. The blockage is mostly recognized by deformations/bumps on the ribbed belt pulley. In addition, the blockage can be recognized by the abraded rubber in the area of the ribbed belt pulley. The A/C compressor is equipped with a protected oil supply, this prevents A/C compressor damage in the event that the system is empty. This means that approximately 40 to 50 cm3 of refrigerant oil remains in the A/C compressor. Only start the engine when the refrigerant circuit is filled. The engine may only be started when the refrigerant circuit is installed correctly. For example; if the refrigerant lines are not connected to A/C compressor, when the engine is running the A/C compressor may heat up (via internal heat generation) so much that the A/C compressor will be damaged. A/C Compressor Regulator Valve -N280- is not activated when the refrigerant circuit is empty and the A/C compressor idles with the engine. If it is necessary to start the engine with a discharged refrigerant circuit: Refrigerant circuit must be fully assembled. At least 1/4 of the prescribed refrigerant oil must be in the A/ C compressor. Do not rev engine higher than 2000 RPM. The engine should only run as long as is absolutely necessary, maximum 10 minutes.

Perform remaining installation operations in reverse order of removal.

A/C COMPRESSOR, GOLF BLUE-E-MOTION

Special tools and workshop equipment required

1. ROB 134 APF or newer model
2. Torque Wrench -V.A.G 1331

Note. The procedure for flushing with refrigerant R134a is described in REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A . Disable the vehicle high voltage system if the refrigerant circuit was flushed with refrigerant R134a, for example, if the A/C compressor is damaged.

Note. Inspect the attachment points for the A/C compressor and engine prior to installing. The contact surfaces must be clean and rust and grease-free. Otherwise, repair the contact surfaces with the contact surface cleaning set -VAS 6410-.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. Extract the refrigerant using the ROB 134 APF (or succeeding model). Check notes, refer to REFRIGERANT CIRCUIT SYSTEM OVERVIEW . When filling and emptying with coolant, the heater and A/C unit refrigerant cut-off valve -N541- and the high voltage battery heater core refrigerant cut-off valve -N542- must be open. Use a voltage of 12 V for the shut-off valves when filling and emptying with coolant.

Scheme 68

Remove the noise insulation.

Disconnect high voltage cable -2- from electrical A/C compressor -V470- -6-.

Note. Do not turn the connector. Danger of causing damage.

Disconnect the connector -1- from electrical A/C compressor -V470- -6-.

Remove bolts-5- and -8- (20 +/- 3 Nm) and refrigerant lines-4- and -9- from the electrical A/C compressor -6-.

Remove bolts-7- (25 +/- 3 Nm), lay the potential equalization cables-3- off to the side, and remove the electrical A/C compressor -6-.

Installing

Installation is carried out in the reverse order while noting the following

Note. Inspect the attachment points for the A/C compressor and engine prior to installing. The contact surfaces must be clean and rust and grease-free. Otherwise, repair the contact surfaces with the contact surface cleaning set -VAS 6410-. The procedure for removing refrigerant 134a from the A/C compressor can be found in the repair manual. Refer to REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A . When filling and emptying with coolant, the heater and A/C unit refrigerant cut-off valve -N541- and the high voltage battery heater core refrigerant cut-off valve -N542- must be open. Use a voltage of 12 V for the shut-off valves when filling and emptying with coolant.

AIR DUCTS

1. «CENTER VENT»(ref-480983-S22811253722012061900000)
2. «DRIVER SIDE OR FRONT PASSENGER SIDE VENT»(ref-480983-S20486624952012061900000)
3. «REAR CHANNEL, FOOTWELL»(ref-480983-S34873756862012061900000)
4. «AIR DISTRIBUTION HOUSING»(ref-480983-S15305573312012061900000)
5. «AIR INTAKE HOUSING»(ref-480983-S24941990842012061900000)
6. «FRESH AIR INTAKE»(ref-480983-S13346603572012061900000)
7. «DRIVER SIDE FOOTWELL VENT»(ref-480983-S14599476512012061900000)
8. «PASSENGER SIDE FOOTWELL VENT»(ref-480983-S12939501672012061900000)

CENTER VENT

Special tools and workshop equipment required

Removal Wedge -3409

Removing

Switch off the ignition.

Remove the center instrument panel trim panel (Golf 2009).

Vehicles with a storage compartment in the center of the instrument panel

Remove the radio.

Remove the center instrument panel cover (Golf 2009).

Vehicles with a radio/navigation system

Remove the radio/navigation system.

Vehicles built through 27 May 2011

Scheme 69

Remove the bolts -1- (1.5 Nm).

Vehicles built from 3 June 2011

Slightly remove the instrument panel center vent -2-.

Remove the 4 clips-arrows- from the vent -1- using the -3409-.

Scheme 70

Disconnect the wiring harness from the emergency lamp switch -E3- and remove the vent from the instrument panel.

Installing

Install in reverse order of removal.

Scheme 71

Removing the vents on both sides is identical.

Removing

Remove the side instrument panel cover.

Reach into the instrument panel and unclip the vent from the instrument panel -1- in direction of -arrow A-.

Installing

Install in reverse order of removal.

REAR CHANNEL, FOOTWELL

Removing

The procedure for removing rear channels is identical for both sides.

Remove the front passenger or driver side seat.

Remove the center console.

Lift floor carpet, unclip rear channel from floor and pull off from heater.

Scheme 72

Installing

Install in reverse order of removal.

When installing the rear channel, first slide it onto the heater -arrow- and then clip it into the floor panel.

AIR DISTRIBUTION HOUSING

Removing

Scheme 73

Remove the heating and A/C unit. Refer to HEATING AND A/C UNIT .

Unplug the connectors on the air distributor housing.

Remove the heat exchanger together with the coolant pipes. Refer to HEAT EXCHANGER .

Remove the bolts -arrows- (1.4 Nm).

Remove the air distributor housing -1- from the heater unit -2-.

Installing

Install in reverse order of removal. When doing this, note the following

Tightening specification for the bolts -arrows- : 1.4 Nm.

AIR INTAKE HOUSING

Removing

Remove the instrument panel.

Loosen the heater and A/C unit on the left side.

Loosen the bolts -1-.

Scheme 74

Lift air intake housing -in direction of arrow A-.

Unhook the air intake housing -in direction of arrow B- from the hook.

Scheme 75

Installing

Install in reverse order of removal. Make sure the housing fits correctly with the mounts -1- in the hooks -2-.

Scheme 76

After installing, function of recirculation door must be checked. Perform the "basic setting" function for the adjustment motor using the Vehicle Diagnostic Tester.

FRESH AIR INTAKE

Removing

Remove the plenum chamber cover.

Scheme 77

Remove the cover -1- from the plenum chamber.

Check Air quality sensor -G238- functionality, refer to AIR QUALITY SENSOR -G238 .

Disconnect connector.

Turn the air quality sensor -1- to the right and remove it.

Scheme 78

Remove the flange nuts -arrows- (2.5 +/- 0.4 Nm) and the air grille.

Installing

Install in reverse order of removal.

Note. The seal must fit correctly in the air grille.

Assembly sequence

Align the air grille on the flange.

Hold the air grille and install the side flange nuts (2.5 +/- 0.4 Nm) and then the center flange nuts.

Scheme 79

DRIVER SIDE FOOTWELL VENT

Removing

Remove the driver side footwell cover.

Remove the driver side storage compartment under the rotary light switch to gain access to the bolt -2-.

Remove the screws -2- (1.5 +/- 0.2 Nm) and then remove the footwell vent -1-.

Scheme 80

Installing

Install in reverse order of removal.

Remove bolt -2- (1.5 +/- 0.2 Nm)

PASSENGER SIDE FOOTWELL VENT

Removing

Remove the glove compartment. Refer to Removal and Installation .

Remove the screws -2- (1.5 +/- 0.2 Nm) and then remove the footwell vent -1-.

Scheme 81

Installing

Install in reverse order of removal.

Note. Note the correct position of the coolant hoses for vehicles with glove compartment cooling.

Note. The air quality sensor -G238- is installed at the right front on the air intake grille in the plenum chamber. The air quality sensor contains a highly sensitive electronic component which can be damaged if it comes in direct contact with solvents, fuels or chemicals. Do not install a sensor that has been kept, for example, in a tool box. Do not store removed sensors in areas where they can come into contact with solvents, fuels and certain chemical compositions (fluids or vapors).

Removing

Remove plenum chamber cover. Refer to Removal and Installation .

Remove cover -1- from plenum chamber.

Disconnect the connector on the air quality sensor.

Release the air quality sensor -1-, turn it and remove it from the bracket on the air intake grille.

Installing

Install in reverse order of removal.

AUXILIARY HEATER HEATING ELEMENT -Z35

Removing

Remove the knee airbag.

Remove the driver footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Note. If the temperature door lever -C- is a position that hinders access to the upper screw -A-. Change the position of the temperature door using the hot and fresh air controls; on vehicles with Climatronic (for example"Hi" setting).

Scheme 82

Scheme 83

Installing

Make sure the ground wire is positioned correctly.

Tighten nut -1- to (9 +/-1 Nm) and the bolt -2- to (1.4 Nm).

Perform remaining installation operations in reverse order of removal.

BELT PULLEY, FIRMA DENSO

1. This type of ribbed belt pulley is installed on "7SEU17C" A/C compressor.
2. Different versions of the ribbed belt pulley may be installed, depending on A/C compressor construction type and engine version.

Scheme 84

1. Cap With Locking Ring Remove carefully using a small screwdriver or needle-nose pliers (pay special attention to ribbed belt pulley when doing this).
2. Drive Plate
3. Circlip Always replace Install on correct side (flat side toward A/C compressor)
4. Spacer
5. Ribbed Belt Pulley The ribbed belt pulley is made of plastics and is sensitive to impact, be especially careful when handling it.
6. A/C Compressor Depending on engine and market version, different versions can be installed. Clean A/C compressor flange before sliding on ribbed belt pulley.
7. Rubber Element Quantity: 6 Decouples the ribbed belt pulley from the A/C compressor input shaft and dampens vibration and noise. For installation, lightly coat rubber elements, fo9r example, with tire mounting paste or a soap solution (as a lubricant).

Removing

Scheme 85

Carefully remove the cap with locking ring-A- using a small screw driver or needle nose pliers for example. Make sure that the ribbed belt pulley is not damaged in the process.

Turn the drive plate -C- and the ribbed belt pulley -D- using a commercially available strap wrench in the -direction of arrow E- and loosen the input shaft -B- (35 +/- 5 Nm) in the -direction of arrow F-.

Remove drive plate -C-.

Scheme 86

Remove locking ring -A-.

Remove the ribbed belt pulley -B-.

Installing

Scheme 87

Remove locking ring -A-.

Clean A/C compressor flange before sliding on ribbed belt pulley.

When installing circlips -A-, note that it cannot be bent open more than is necessary for installation.

Install the ribbed belt pulley -B-.

Insert circlip -A- on correct side, the side with beveled insertion edge -C- faces away from A/C compressor (install flat side facing A/C compressor).

Insert rubber elements -D- in belt pulley -B- according to illustration.

Note. When installing drive plate, coat the rubber element -D- lightly with, for example, tire mounting paste or soap solution (as sliding compound). Install protective jaws -2- between vice and the A/C compressor in order to avoid damaging the A/C compressor mount.

Position the drive plate -C- between the rubber elements until they touch the A/C compressor shaft -B-.

Secure the drive plate -1- with a commercially available strap wrench in the -direction of the arrow A- and tighten the driveshaft with a torque wrench in the -direction of the arrow B- (35 +/- 5 Nm).

Scheme 88

Install cap with locking ring.

TEMPERATURE REGULATOR DOOR MOTOR - V68

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System VAS 5051B

Removing

Remove the knee airbag. Refer to Removal and Installation .

Remove the trim in the left footwell of the center console (it is not necessary to remove the trim any further).

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Remove the data bus on board diagnostic interface -J533-. Refer to DATA BUS ON BOARD DIAGNOSTIC INTERFACE -J533 .

Scheme 89

Remove the bolts -3- (9 ± 1.3 Nm).

Note. The bolts -1- are not to be removed. Do not remove the bracket -2-.

Push the mount -1- in the direction of the brake pedal -arrow- and secure it there with binding components (such as with cable ties).

Scheme 90

Mark connector -C- to control motor (danger of interchange with other connectors of same construction).

Scheme 91

Disconnect connector -C- on temperature regulator door motor -V68-.

Remove cover -A-.

Remove the securing bolts -D- (1.4 Nm) and remove the temperature regulator door motor -B-.

Disengage control motor lever -E- from connecting rod -F-.

Installing

Note. Optimized motors are marked with an X.

For improved installation, use a raised head screw N 103 254 01 which has been shortened approx. 2 mm.

Remove the mount -1- from the old temperature regulator door motor using, for example, a diagonal cutter.

Scheme 92

Attach the new temperature regulator door motor that is marked with an "X" to the mount -3- using the shortened raised head screw -2- and the removed mount -1-.

Scheme 93

Note. After installing, function of temperature door must be checked. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

DEFROSTER DOOR MOTOR -V107

Special tools and workshop equipment required

1. Vehicle Diagnostic Tester or newer model.
2. Vehicle diagnosis, testing and information system VAS 5051B or newer model.

Perform the following work first

Turn off all electric consumers.

Switch off the ignition.

Remove the key.

Removing

Remove the instrument panel.

Remove data bus on board diagnostic interface -J533-. Refer to DATA BUS ON BOARD DIAGNOSTIC INTERFACE -J533 .

Remove the bolts -1- and -3- (9 ± 1.3 Nm).

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Remove the knee airbag bracket. Refer to Removal and Installation .

Remove bracket -2-.

Mark connector -C- to control motor (danger of interchange with other connectors of same construction).

Scheme 94

Disconnect connector -C- on defroster door motor -V107-.

Remove securing bolts -A- and remove defroster door motor -B-.

Disengage control motor lever -E- from connecting rod -D-.

Installing

Install in reverse order of removal. When doing this, note the following

The tightening specification for the screws -1- and -3- is 9 ± 1.3 Nm.

Note. After installing, function of defroster door must be checked. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

RECIRCULATION DOOR MOTOR -V113

Special tools and workshop equipment required

Note. Position of recirculating air door must not be changed.

Removing

Remove the glove compartment. Refer to Removal and Installation .

Scheme 95

Remove cover -1-.

Disconnect the connector from the air recirculation flap motor -V113- -2-.

Remove the air recirculation flap motor -2- from the mounts.

Installing

Install in reverse order of removal.

Note. After installing, function of recirculation door must be checked. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

LEFT TEMPERATURE DOOR MOTOR -V158

Special tools and workshop equipment required

1. Vehicle diagnosis, testing and information system VAS 5051B or newer model.

Removing

Turn off all electric consumers

Remove the key.

Remove the knee airbag. Refer to Removal and Installation .

Remove the trim in the left footwell of the center console (it is not necessary to remove the trim any further).

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Remove data bus on board diagnostic interface -J533-. Refer to DATA BUS ON BOARD DIAGNOSTIC INTERFACE -J533 .

Remove the bolts -3- (9 ± 1.3 Nm).

Note. The bolts -1- are not to be removed. Do not remove the bracket -2-.

Push the bracket -1- toward the brake pedal -arrow- and secure it there using a cable tie.

Mark connector -C- to control motor (danger of interchange with other connectors of same construction).

Disconnect connector -C- on left temperature flap motor -V158-.

Remove cover -A-.

Remove bolts -D- (1.4 Nm) and remove left temperature flap motor -B-.

Disengage control motor lever -E- from connecting rod -F-.

Installing

Install in reverse order of removal. When doing this, note the following

The tightening specification for the bolts -1- and -3- is 9 ± 1.3 Nm.

Note. Optimized motors are marked with an X.

For improved installation, use a raised head screw N 103 254 01 which has been shortened approx. 2 mm.

Remove the mount -1- from the old left temperature flap motor using, for example, a diagonal cutter.

Mount the new left temperature flap motor marked with an X using the shortened raised head screw -2- to the detached mount -1- to the bracket -3- on the blower case.

Left temperature flap motor screws: 1.4 Nm.

Note. After installing, function of temperature door must be checked. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

RIGHT TEMPERATURE DOOR MOTOR -V159

Special tools and workshop equipment required

1. Vehicle diagnosis, testing and information system VAS 5051B or newer model.

Removing

Turn off all electric consumers.

Switch off the ignition.

Remove the key.

Remove the glove compartment. Refer to Removal and Installation .

Remove the footwell vent on the front passenger side. Refer to FRONT PASSENGER SIDE FOOTWELL VENTS .

Scheme 96

Disconnect harness connector from right temperature flap motor -V159-.

Remove the securing bolts -1- (1.4 Nm) and remove the right temperature flap motor.

Unhook brace -2- from right temperature flap motor.

Installing

Install in reverse order of removal.

Note. After installing, function of right temperature door must be checked. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

FRESH AIR/RECIRCULATING AIR/BACK PRESSURE DOOR MOTOR -V425

Special tools and workshop equipment required

1. Vehicle diagnosis, testing and information system VAS 5051B or newer model.

Removing

Turn off all electric consumers.

Switch off the ignition.

Remove the key.

Remove the glove compartment. Refer to Removal and Installation .

Remove the bolts -1- (1.4 Nm).

Scheme 97

Turn the fresh air/recirculating air/back pressure door motor -V425- -2- approximately 15° in -direction of arrow- and then pull it off the air intake housing.

Disconnect the connector -1- from the fresh air/recirculating air/back pressure door motor.

Scheme 98

Note. Position of air flow door must not be changed.

Installing

Install in reverse order of removal. When doing this, note the following

The fresh air/recirculating air/back pressure door motor fits in only one position on the curved washer.

Scheme 99

Note. After installing, check the function of the back pressure and recirculation door. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

FRESH AIR/RECIRCULATING AIR/BACK PRESSURE DOOR ADJUSTER

Removing

Remove the fresh air/recirculating air/back pressure door motor -V425-. Refer to FRESH AIR/RECIRCULATING AIR/BACK PRESSURE DOOR MOTOR -V425 .

Open the retainers -arrows- on the adjusting lever -1-.

Scheme 100

Remove the adjusting lever from the curved washer.

Remove the curved washer -2- from the air intake housing.

Installing

Note. When installing the curved washer, make sure the guide pin for the air flow door adjusting lever is seated in the groove.

Install the curved washer -1- on the air intake housing.

Scheme 101

Note. Make sure the guide pin for the recirculation air door adjusting lever is seated in the curved washer groove.

Mount and latch the recirculation air door adjusting lever.

FRONT AIR DISTRIBUTION DOOR MOTOR -V426- AND POSITION SENSOR -G642

Removing

Turn off all electric consumers.

Switch off the ignition.

Remove the key.

Remove the instrument panel. Refer to Removal and Installation .

Scheme 102

Disconnect the connector on the front air distribution flap motor -V426-.

Remove the screws -1- and then remove the front air distribution flap motor.

Installing

Install in reverse order of removal.

Make sure the flap works correctly after installing the front air distribution flap motor.

Note. Initiate Basic Setting function with VAS 5051B (or succeeding model). Refer to A/C SYSTEM WITH AUTOMATIC CONTROL, CLIMATRONIC, CHECKING AND ADJUSTING COMPONENTS .

AIR DISTRIBUTION DOOR MOTOR -V428

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System V AS 5051B

Removing

Remove the instrument panel. Refer to Removal and Installation .

Disconnect the connector on the front air distribution flap motor -V426-.

Scheme 103

Remove the bolts (1.5 Nm) -arrows-.

Remove the air distribution door motor -1-.

Installing

Make sure the door works correctly after installing the air distribution door motor. Initiate the "basic setting" using the vehicle diagnostic tester

Install in reverse order of removal.

DISPLAY AND CONTROL UNIT, CLIMATRONIC

Note. The Climatronic control module -J255- and the A/C control head -E87- are one component that cannot be disassembled. Perform a basic setting and an adaptation A/C compressor first start either in Guided Fault Finding or Guided Functions when a new Climatronic control module display -E87- and a Climatronic control module are installed. Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Removing

Remove the A/C control / heater control trim (Golf from MY 2009). Refer to Removal and Installation .

Scheme 104

Remove the screws -2- (1.5 ± 0.2 Nm) and remove the Climatronic control module from the instrument panel.

Disconnect harness connectors from A/C control head.

Installing

Note. Perform a basic setting and an adaptation A/C compressor first start either in Guided Fault Finding or Guided Functions when a new Climatronic control module display and a Climatronic control module are installed.

Installation is in reverse order of removal. Note the tightening specification 1.5 ± 0.2 Nm for the screws.

DISPLAY AND CONTROL UNIT, ELECTRIC MANUAL

Note. Perform a basic setting and an adaptation A/C compressor first start either in Guided Fault Finding or in Guided Functions when installing a new A/C control module -J301-. Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Removing

Remove the A/C control / heater control trim (Golf from MY 2009). Refer to Removal and Installation .

Scheme 105

Remove the screws -arrows- and remove the controls from the center console.

Disconnect the connector on the control.

Installing

Note. Perform a basic setting and an adaptation A/C compressor first start either in Guided Fault Finding or in Guided Functions when installing a new A/C control module -J301-.

Installation is in reverse order of removal. Note the tightening specification 1.5 ± 0.2 Nm for the screws.

DUST AND POLLEN FILTER

Removing

Scheme 106

Remove the plastic screws -2- and the partition -1-.

Release cover -1- in direction of arrow.

Scheme 107

Remove dust and pollen filter downward out of heater.

Installing

Install in reverse order of removal. When doing this, note the following

Note installation position of the dust and pollen filter during assembly.

Scheme 108

EVAPORATOR

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Disassemble the heating and A/C unit: Refer to HEATING AND A/C UNIT

With Climatic, refer to HEATER AND A/C UNIT OVERVIEW, CLIMATIC .

With Climatronic, refer to HEATER AND A/C UNIT OVERVIEW, CLIMATRONIC .

Disassemble evaporator housing. Refer to EVAPORATOR HOUSING .

Scheme 109

Remove evaporator -A- from lower section of evaporator housing.

Installing

Note. Before inserting the evaporator, check condensation water drain and clean drain if necessary. Before inserting evaporator, clean evaporator housing and the evaporator if necessary.

When inserting evaporator -A- into lower section of evaporator housing and when assembling both housing halves, ensure seal -F- is not damaged.

Check seal -F- (it must be glued all around) before inserting evaporator.

Place bracket -C- and seal / insulation -B- onto connecting pipe of evaporator -D- and -E-.

Insert evaporator -A- into lower section of evaporator housing as shown in the illustration.

Note. After assembling both housing halves, check seal / insulation -B- for correct seating at pass-through for both refrigerant lines -D- and -E-. Check seating of bracket -C- on both refrigerant lines -D- and -E- for correct seating. If heat protection insulation -B- is missing or not installed correctly, it can cause reduced performance of the A/C system (change of adjusted control characteristics of expansion valve due to radiant heat).

EVAPORATOR TEMPERATURE SENSOR -G308- OR EVAPORATOR VENT TEMPERATURE SENSOR -G263

Removing

Remove the right trim panel inside the footwell -1-. Refer to Removal and Installation .

Scheme 110

Remove connector on evaporator temperature sensor -G308- or evaporator vent temperature sensor -G263- -1-.

Scheme 111

Rotate evaporator temperature sensor or evaporator vent temperature sensor in -direction of arrow- and remove.

Installing

Install in reverse order of removal.

FRESH AIR BLOWER -V2

1. Fresh Air Blower V2, «FRESH AIR BLOWER -V2-, MANUAL CONTROLS»(ref-480983-S10894148852012061900000)
2. Fresh Air Blower V2, Climatronic «FRESH AIR BLOWER -V2-, CLIMATRONIC»(ref-480983-S18659339742012061900000)

FRESH AIR BLOWER -V2-, MANUAL CONTROLS

Removing

The fresh air blower is accessible from footwell on front passenger side.

Remove the plastic screws -2- and the partition -1-.

Disconnect harness connector -A- from fresh air blower.

Remove the bolt -B- (1 Nm) from the fresh air blower.

Release the retainer -2- and turn the fresh air blower in -direction of arrow-.

Scheme 112

Remove the fresh air blower from the heater.

Installing

Install in reverse order of removal.

FRESH AIR BLOWER -V2-, CLIMATRONIC

Removing

The fresh air blower is accessible from footwell on front passenger side.

Remove the glove compartment. Refer to Removal and Installation .

Remove the plastic screws -2- and the partition -1-.

Disconnect harness connector -A- from fresh air blower.

Remove the bolt -B- (1 Nm) from the fresh air blower.

Release the retainer -2- and turn the fresh air blower in -direction of arrow-.

Remove the fresh air blower from the heater.

Installing

Install in reverse order of removal.

FRESH AIR BLOWER CONTROL MODULE -J126

Removing

Remove the fresh air blower -V2-. Refer to FRESH AIR BLOWER .

Scheme 113

Disconnect connector -1- to fresh air blower.

Remove bolts -arrows-.

Installing

Install in reverse order of removal.

FRESH AIR BLOWER SERIES RESISTOR WITH FUSE -N24

Removing

The fresh air blower is accessible from footwell on front passenger side.

Remove the glove compartment. Refer to Removal and Installation .

Remove the plastic screws -2- and the partition -1-.

Disconnect the connector -1- on the fresh air blower series resistor with fuse.

Push the retainer in -direction of arrow- and remove the fresh air blower series resistor with fuse from the heater.

Installing

Install in reverse order of removal.

GLOVE COMPARTMENT COOLING

Removing

Remove the glove compartment. Refer to Removal and Installation .

Remove the hose for the glove compartment cooling -1- from the valve -3-.

Scheme 114

Remove the hose for the glove compartment cooling -1- from the connection -2- on the heater and A/C unit.

Installing

Install the hose for the glove compartment cooling in reverse order. When doing this, note the following

1. The hose fits in only one position. The notch must align with the tab.
2. The hose must not get bent or squeezed.

HEATER AND A/C UNIT

Special tools and workshop equipment required

1. ROB 134 APF or succeeding model.
2. Drip tray for shop crane VAS 6208
3. Hose clamps up to 40 mm diameter 3093
4. Compressed air gun, commercially available

Removing

Note. To improve accessibility, additional components e.g. engine cover must be removed (depending on engine version). Refer to [For transmission(s) 02E, 02Q] [For engine(s) CJAA] Removal and Installation or [For transmission(s) 0A4, 09G] [For engine(s) CBTA, CBUA] Removal and Installation .

Extract refrigerant e.g. using VAS 6007A, only then open the refrigerant circuit. Observe notes. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Remove the instrument panel. Refer to Removal and Installation .

Place VAS 6208 under the engine.

Scheme 115

Mark coolant hoses -1-.

Clamp off the coolant hoses -1- using 3093 and disconnect the coolant hoses to the heater core.

Scheme 116

Connect a section of hose -A- onto upper connection.

Hold a container -B- under the lower connection -C-.

Using a compressed air gun, carefully blow residual coolant out of heater core at heater core connection.

Only for Vehicles with a Heat Shield in Front of the Expansion Valve

Remove the nut -1- (6 ± 0.9 Nm).

Remove the clamps -2- and the heat shield -3-.

Scheme 117

Loosen the clips -2- and remove the heat shield -3-.

All Vehicles

Scheme 118

From inside the engine compartment, remove the bolts (10 +/- 1 Nm), -2- from the refrigerant pipes -2-.

Remove the refrigerant pipes from the expansion valve -3-.

Note. Seal open pipe connections. To seal off all open connections on expansion valve, sealing caps from a replacement expansion valve can be used (preventing dirt and moisture from entering the system).

Cover floor carpet in vehicle interior with leakproof foil and absorbent paper.

Note. Make a note of the screw lengths and their location.

Scheme 119

1. Bolt 4.5 ± 0.7 Nm On the lower right side on the cable bracket for the heater and air conditioner near the plenum chamber bulkhead.
2. Bolts 4.5 ± 0.7 Nm
3. Cable Bracket
4. Heating and A/C Unit
5. Bracket
6. Bolts 8 ± 1 Nm
7. Subframe NOTE: There are two versions of the assembly carrier -7-. On the version made of steel, the supports are welded to the assembly carriers -8- and -10-. On the version made of aluminum, the supports are attached to the assembly carriers -8- and -10- with bolts. The illustration shows the version made of steel.
8. Right Support
9. Bolts 20 ± 3 Nm
10. Left Support
11. Bolts 9 ± 1.3 Nm
12. Bracket
13. Bolts 9 ± 1.3 Nm

Remove the condensation water hose from the heater and air conditioner. Refer to CONDENSATION WATER DRAIN HOSE ON HEATING AND A/C UNIT .

Disconnect the connectors from the heater and air conditioner.

1. All cable ties opened or cut during the removal of the A/C system must be reinstalled at the same locations during installation.
2. The air conditioning wiring harness is removed with the heater and air conditioner.

Remove the bolts -6- and the holder -5-.

Remove screws -9-.

Remove the bolts -11- and -13- and bracket -12-.

Remove the subframe -7-.

Note. On the version made out of aluminum, only the supports -8- and -10- need to be removed. Tightening specification for the upper bolts on the support: 9 +/- 1.3 Nm.

Remove the bolts -1- and -2- from the cable bracket -3-.

To be able to reach the bolt -1-, the heating and A/C unit on the driver side must be pulled out slightly from the bulkhead.

1. When removing the heater and A/C unit, make sure the two coolant pipes on the heater core do not get caught and bent or damaged on plenum chamber or noise insulation pan.
2. Pay attention to the wiring harness. The individual wire connections could get damaged when pulling on harness.

Remove heating and A/C unit.

Installing

Installation is carried out in the reverse order while noting the following

Note. The assistance of a second technician is necessary to install the heating and A/C unit.

Note. Guide both heater core coolant pipes (from inside the engine compartment) through the seals with the help of a second technician when installing the heater and A/C unit. Refer to

Make sure the condensation water hose fits correctly. Refer to CONDENSATION WATER DRAIN HOSE ON HEATING AND A/C UNIT .

Add coolant.

Fill with R134a refrigerant and refrigerant oil. Refer to CAPACITIES .

Scheme 120

Note. Make sure the seal -A- is installed correctly.

HEATER CORE

Special tools and workshop equipment required

1. Drip tray for shop crane VAS 6208
2. Hose clamps up to 40 mm diameter 3093
3. Compressed air gun, commercially available

Place -VAS 6208- under the engine.

Clamp the coolant hoses -1- using the -3093- and remove the coolant hoses from the heater core.

Connect a section of hose -A- to the upper connection on the heater core.

Hold a container -B- under the lower connection -C-.

Using a compressed air gun, carefully clear out any coolant still inside the heater core into the container -B-.

Depending on the engine, additional parts may need to be removed such as the charge air pipe.

Loosen the bolt -1- on the connection flange between the heater core connections, but do not remove it.

Scheme 121

Note. By loosening the screw -1-, the coolant pipes are loosened and it is easier to remove the heater core.

Remove the knee airbag mount.

Remove the storage compartment for the driver side trim panel.

Remove the trim in the left footwell of the center console (it is not necessary to remove the trim any further).

Remove the driver footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Remove the bolts -A- and the cover -B-.

Note. There are different versions of cover -B-. The illustration shows the version with Auxiliary Air Heater Heating Element -Z35-. If the temperature door lever -C- is a position that hinders access to the upper screw -A-. Change the position of the temperature door using the hot and fresh air controls; on vehicles with Climatronic (for example"Hi" setting).

Cover the carpet the in area under heater core with waterproof foil and water absorbing paper.

Open the clamps -A- and remove the coolant pipes from the heater core.

Remove the heater core from the heater.

Scheme 122

Installing

Install in reverse order of removal. When doing this, note the following

Inspect the seals -A- and -B- attached on the heater core. Only install the heater core if the seals are not damaged.

Scheme 123

Note. An incorrectly glued seal can roll up into heater when sliding in the heater core. Cold air may flow past heater core if seal is damaged or not properly fitted.

Scheme 124

Install the heater core into the heater.

Replace the sealing rings -1- coat them with coolant before installing.

Scheme 125

Note. If pipe clamps are deformed, replace them.

Attach the coolant pipes to the heater core.

Pipe clamps -A- must be able to be twisted slightly when installing onto the coolant pipes.

Pipe clamps -A- must be installed as shown in the illustration.

Tighten the pipe clamps -A- to 2 Nm.

Scheme 126

Make sure the clamps -A- are tight after tightening the screws. They must completely enclose the flange on the heater core and coolant pipe and must not come in contact with other components.

Tighten the connection flange bolt -1- between the heater core connections to 2 Nm.

After assembling the grommet -C-, check that the plenum chamber bulkhead is in the correct position.

Seal flange for coolant pipes to heater core -A- and for expansion valve (to evaporator) -B- at pass-through of grommet -C- with silicon adhesive sealant if necessary (to prevent water from penetrating).

Scheme 127

Replace the seals.

Replace all the coolant after replacing the heater core.

Inspect the coolant circuit for leaks. Pay close attention to the connections between the coolant pipes and the heater core when doing this.

HEATER CORE COOLANT PIPE

Removing

Remove the heater in order to replace the coolant pipes that run from the engine compartment to the heater core. Refer to HEATER AND A/C UNIT .

Remove the bolt -1- for the connection flange between the heater core connections.

Scheme 128

Vehicles with Climatic

Remove the temperature regulator door motor -V68-.

Vehicles with Climatronic

Remove the left temperature regulator door motor -V158-. Refer to LEFT TEMPERATURE DOOR MOTOR -V158 .

For all vehicles

Remove the bolts -A- and the cover -B-.

Open the clamps -A- and remove the coolant pipes from the heater core.

Scheme 129

Installing

Coat sealing rings -1- with coolant before installing.

Install the seals -1- into the connection in the heater core.

Note. Ensure sealing rings are installed on the proper side, as shown in the illustration. If pipe clamps are deformed, replace them.

Attach the coolant pipes to the heater core.

Always replace the seals -1-. Coat sealing rings -1- with coolant before installing.

Scheme 130

Note. If pipe clamps are deformed, replace them.

Pipe clamps -A- must be able to be twisted slightly when installing onto the coolant pipes.

Pipe clamps -A- must be installed as shown in the illustration.

Tighten the pipe clamps -A- to 2 Nm.

Make sure the clamps -A- are tight after tightening the screws. They must completely enclose the flange on the heater core and coolant pipe and must not come in contact with other components.

Tighten the connection flange bolt -1- between the heater core connections to 2 Nm.

Install the heater. Refer to HEATER AND A/C UNIT .

OUTSIDE AIR TEMPERATURE SENSOR -G17

Removing

Reach through the air intake inside the bumper.

Unclip outside air temperature sensor -G17- -1- from bracket and disconnect electrical connector.

Scheme 131

Installing

Installation is carried out in the reverse order, when doing this note the following

Note. Ensure electrical connector is seated correctly (water entry).

PASSENGER COMPARTMENT FORCED AIR VENTILATION

Special tools and workshop equipment required

1. Removal Wedge -3409

Removing

Remove the rear bumper.

Release the tabs -2- using the -3409- -1- and remove the vent frame -3- from the side panel.

Scheme 132

Installing

Install in reverse order of removal.

1. «CONDENSER»(ref-480983-S19036233182012061900000)
2. «DRYER CARTRIDGE»(ref-480983-S35245455892012061900000)
3. «FLUID RESERVOIR»(ref-480983-S34624433632012061900000) .
4. «EVACUATING AND CHARGING VALVE, LOW AND HIGH PRESSURE SIDES»(ref-480983-S20416075202012061900000)
5. «EXPANSION VALVE»(ref-480983-S18882537642012061900000)
6. «FLUID RESERVOIR»(ref-480983-S34624433632012061900000)
7. «HEATER AND A/C UNIT REFRIGERANT CUT-OFF VALVE -N541»(ref-480983-S16876179462012061900000)
8. «HIGH PRESSURE SENSOR -G65-GASOLINE»(ref-480983-S00500704802012061900000)
9. «HIGH PRESSURE SENSOR -G65- COMMON RAIL»(ref-480983-S39130057442012061900000)

CONDENSER

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331/ (5 to 50 Nm)
2. ROB 134 APF or succeeding model.

Note. Refrigerant must be extracted before hand using VAS 6007A. The previously used service stations can still be used. To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Perform following work first

Switch off all electrical consumers.

Switch off ignition.

Remove ignition key.

Extract refrigerant e.g. using ROB 134 APF.

Note. Environmentally hazardous draining of refrigerant is an offense punishable by law.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Remove the front bumper. Refer to Removal and Installation .

Remove the lock carrier. Refer to Removal and Installation .

Remove the bolts -1- (12 ± 1.8 Nm).

Scheme 133

Remove the refrigerant lines -2- from the connection -4- on the condenser.

Seal off the line connections.

Note. Always replace the seals -3-.

Scheme 134

1. Condenser Secure to radiator with 4 bolts
2. Bolt 5 ± 0.5 Nm
3. Radiator
4. Bolts Quantity: 4 5 ± 0.5 Nm
5. Reservoir with Dryer or Dryer Bag Condenser manufactured by Showa: Reservoir with dryer, removing and installing, refer to «FLUID RESERVOIR WITH DRYER»(ref-480983-S34624433632012061900000) . Condenser manufactured by Modine: Dryer bag, removing and installing, refer to «DRYER CARTRIDGE»(ref-480983-S35245455892012061900000) .

DRYER CARTRIDGE

Note. Observe notes. Refer to REFRIGERANT CIRCUIT COMPONENTS . Refrigerant must be extracted before hand using VAS 6007A. The previously used service stations can still be used. To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Extract refrigerant e.g. using VAS 6007A, only then open the refrigerant circuit.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Remove, depending on the charge air system engine components.

Loosen the cooler packet from out of the mount and tilt it toward the rear.

Remove the label on the cap.

Remove the cap -1- with a 50 TORX socket.

Scheme 135

Push the cover -1- down slightly and remove the circlip -arrow-.

Install the M12 bolt into the cover and carefully pull it out of the fluid container -2-.

Scheme 136

Remove the dryer bag using a commercially available pick-up tool -in direction of arrow- from the condenser.

Scheme 137

Make a welding wire (ø 2 mm) to the following dimensions.

Scheme 138

a - 380 mm

b - maximum 7 mm

c - maximum 6 mm

Hook the welding wire to the strainer exactly as illustrated to prevent damaging the condenser.

Scheme 139

Carefully remove the filter (strainer) -2- from the condenser with the welding wire -1-.

Installing

Install the new strainer in the condenser.

Insert the dryer bag into the condenser.

Perform remaining installation operations in reverse order of removal.

EVACUATING AND CHARGING VALVE, LOW AND HIGH PRESSURE SIDES

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1783
2. A/C Service Station VAS 6007A (or succeeding model)
3. "Ratchet Insert 1/4" VAS 6234
4. Adapter set with service connection T10364

Note. Environmentally hazardous draining of refrigerant is an offense punishable by law. To prevent the ingress of dampness, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Remove the cap -3-.

Scheme 140

Extract the refrigerant circuit using ROB 134 APF (or subsequent models). Then immediately replace the valve -2-.

Remove the valve insert -2- (2 +/- 0.2 Nm) from the refrigerant pipe with the proper adapter -4-. Hold the valve mount -1- secure with a suitable tool when doing this.

Installing

Install in reverse order of removal.

EXPANSION VALVE

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331/ (5 to 50 Nm)
2. ROB 134 APF or succeeding model.

Functions

The expansion valve atomizes the streaming refrigerant and controls the flow quantity so that the vapor is gaseous only at the evaporator outlet, depending on the heat transmission.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Note. Refrigerant must be extracted before hand using ROB 134 APF or equivalent. The previously used service stations can still be used. To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs. On some vehicles, connecting pipe from charge air cooler should be removed.

Only for Vehicles with a Heat Shield in Front of the Expansion Valve

Remove the nut -1- (6 ± 0.9 Nm).

Loosen the clips -2- and remove the heat shield -3-.

All Vehicles

Scheme 141

1. Bolts 10 ± 1 Nm Quantity: 2
2. Refrigerant Lines on Expansion Valve
3. O-ring 13.7 mm; 2.5 mm
4. Expansion Valve
5. O-ring 14 mm; 1.82 mm Coat with refrigerant oil when installing
6. O-ring 10.8 mm; 1.82 mm Coat with refrigerant oil when installing
7. O-ring 9.5 mm; 2.5 mm
8. Cylindrical Combination Bolt 5 Nm

Removing

Extract refrigerant using ROB 134 APF or equivalent.

Remove screws -1- and disconnect refrigerant lines -2- from expansion valve.

Remove screws -8- and remove expansion valve -4-.

Installing

Install in reverse order of removal.

HEATER AND A/C UNIT REFRIGERANT CUT-OFF VALVE -N541

Special tools and workshop equipment required

1. Torque Wrench -V.A.G 1331/- (5 to 50 Nm)
2. ROB 134 APF or succeeding model.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. Refrigerant must be extracted before hand using ROB 134 APF. The previously used service stations can still be used. To prevent the entry of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Disconnect the connector -1- from Heater and A/C unit refrigerant cut-off valve -2-.

Remove union nut -3- from Heater and A/C unit refrigerant cutoff valve -2-.

Scheme 142

Remove heater and A/C unit refrigerant cut-off valve -2-.

Installing

Installation is carried out in the reverse order while noting the following

Note. Note the direction of coolant flow when installing (arrow on component). When filling and emptying with coolant, the heater and A/C unit refrigerant cut-off valve and the high voltage battery heater core refrigerant cut-off valve -N542- must be open. Use a voltage of 12 V for the shut-off valves when filling and emptying with coolant.

HIGH PRESSURE SENSOR -G65- GASOLINE

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Assembly tool SW 17 V.A.G 1331/6

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Remove noise insulation from engine. Refer to Description and Operation .

Disconnect harness connector from high pressure sensor -1-.

Note. If when loosening the high pressure sensor for longer than 1 second coolant is leaking, the high pressure sensor should be secured again and the coolant drained. The check valve in the refrigerant lines is defective and must be replaced

Remove the high pressure sensor -1- from the refrigerant line connection.

Scheme 143

The high pressure sensor -1- may also be installed on a different side in the vicinity of the condenser, depending on the engine version.

Installing

Install in reverse order of removal. When doing this, note the following

Replace the O-ring -2-.

The high pressure sensor torque is 8 +/- 1 Nm.

HIGH PRESSURE SENSOR -G65- COMMON RAIL

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Assembly tool SW 17 V.A.G 1331/6

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Disconnect the connector from the high pressure sensor

Note. If when loosening the high pressure sensor for longer than 1 second coolant is leaking, the high pressure sensor should be secured again and the coolant drained. The check valve in the refrigerant lines is defective and must be replaced.

Disconnect the connector from the high pressure sensor.

Remove the high pressure sensor -G65- -1- from the refrigerant line -2-.

Scheme 144

Installing

Install in reverse order of removal. When doing this, note the following

Replace the o-ring.

Note. High pressure sensor tightening specification: 8 ± 1 Nm.

EXPANSION VALVE, GOLF BLUE-E-MOTION

Special tools and workshop equipment required

1. Torque wrench V.A.G 1331/ (5 to 50 Nm)
2. ROB 134 APF or succeeding model.

Functions

The expansion valve atomizes the streaming refrigerant and controls the flow quantity so that the vapor is gaseous only at the evaporator outlet, depending on the heat transmission.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. Refrigerant must be extracted before hand using ROB 134 APF or equivalent. The previously used service stations can still be used. To prevent the ingress of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs. -- Remove charging unit 3.

Scheme 145

1. Bolts 10 ± 1 Nm Quantity: 2
2. Refrigerant Lines on Expansion Valve
3. O-ring 13.7 mm; 2.5 mm
4. Expansion Valve
5. O-ring 14 mm; 1.82 mm Coat with refrigerant oil when installing
6. O-ring 10.8 mm; 1.82 mm Coat with refrigerant oil when installing
7. O-ring 9.5 mm; 2.5 mm
8. Cylindrical Combination Bolt 5 Nm

Removing

Extract refrigerant using ROB 134 APF or equivalent.

Remove screws -1- and disconnect refrigerant lines -2- from expansion valve.

Remove screws -8- and remove expansion valve -4-.

Installing

Install in reverse order of removal.

Note. When filling and emptying with coolant, the heater and A/C unit refrigerant cut-off valve -N541- and the high voltage battery heater core refrigerant cut-off valve -N542- must be open. Use a voltage of 12 V for the shut-off valves when filling and emptying with coolant.

HIGH VOLTAGE BATTERY HEAT EXCHANGER - VX63

Special tools and workshop equipment required

1. Drip Tray For Workshop Hoist -VAS6208
2. Hose Clamps up to 40 mm -3093
3. A/C service station -ROB 134APF- or succeeding model.
4. Torque Wrench -V.A.G 1410/
5. Spring Type Clip Pliers -VAS 5024A

Scheme 146

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. If coolant circuit is opened, it must be bled. If drive motor is warm, coolant system is pressurized. Release pressure before repairs, if necessary. Refrigerant must be extracted before hand using ROB 134 APF. The previously used service stations can still be used. To prevent the entry of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Clamp the coolant hoses using the -3093-.

Loosen clamps -1- and remove coolant hoses from high voltage battery heat exchanger -2-.

Scheme 147

Remove screws -4-.

Remove refrigerant lines-5- from the high voltage battery heat exchanger -2-.

Remove bolts-3- (3 +/- 0.3 Nm) and remove high voltage battery heat exchanger -2-.

Installing

Installation is carried out in the reverse order while noting the following

Note. Bleed the coolant circuit for the high voltage battery heat exchanger after it is installed. Information about coolant circuit bleeding can be found with the E-Fieldteam.

Always replace O-Ring and moisten with refrigerant oil.

Note. When filling and emptying with coolant, the heater and A/C unit refrigerant cut-off valve -N541- and the high voltage battery heater core refrigerant cut-off valve -N542- must be open. Use a voltage of 12 V for the shut-off valves when filling and emptying with coolant.

HIGH VOLTAGE BATTERY HEATER CORE REFRIGERANT CUT-OFF VALVE -N542

Special tools and workshop equipment required

1. Torque Wrench -V.A.G 1331- (5 to 50 Nm)
2. ROB 134 APF or succeeding model.

Removing

When working on the refrigerant circuit, note the information, refer to REFRIGERANT CIRCUIT, SPECIALIZED REPAIRS .

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. Refrigerant must be extracted before hand using ROB 134 APF The previously used service stations can still be used. To prevent the entry of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

Disconnect the connector -2- from the high voltage battery heater core refrigerant cut-off valve -3-.

Scheme 148

Remove union nut -1- from the heater and A/C unit refrigerant cut-off valve -N541- -3-.

Remove Heater and A/C unit refrigerant cut-off valve -N541- -3-.

Installing

Installation is carried out in the reverse order while noting the following

Note. Note the direction of coolant flow when installing (arrow on component) When filling and emptying with coolant, the heater and A/C unit refrigerant cut-off valve -N541- and the high voltage battery heater core refrigerant cut-off valve -N542- must be open. Use a voltage of 12 V for the shut-off valves when filling and emptying with coolant.

SUNLIGHT PHOTO SENSOR -G107- OR SUNLIGHT PHOTO SENSOR 2 -G134

Special tools and workshop equipment required

1. Trim removal wedge 3409

Removing

Unclip Sunlight Photosensor -1- in direction of arrow out of instrument cluster.

Scheme 149

Disconnect the connector.

Installing

Install in reverse order of removal.

TEMPERATURE SENSORS

1. «LEFT VENT TEMPERATURE SENSOR -G150»(ref-480983-S22306144882012061900000)
2. «RIGHT VENT TEMPERATURE SENSOR -G151»(ref-480983-S35685761862012061900000)
3. «CENTER VENT TEMPERATURE SENSOR - G191»(ref-480983-S25293945302012061900000)
4. «FOOTWELL VENT TEMPERATURE SENSOR - G192»(ref-480983-S27283414082012061900000)
5. «LEFT FOOTWELL VENT TEMPERATURE SENSOR -G261»(ref-480983-S32475514282012061900000)
6. «RIGHT FOOTWELL VENT TEMPERATURE SENSOR -G262»(ref-480983-S31802762032012061900000)

LEFT VENT TEMPERATURE SENSOR -G150

Removing

Remove side instrument panel cover. Refer to Removal and Installation .

Scheme 150

Disconnect the connector on the left vent temperature sensor -G150-.

Turn the left vent temperature sensor -1- 90° and remove it from the instrument panel.

Installing

Install in reverse order of removal.

RIGHT VENT TEMPERATURE SENSOR -G151

Removing

Scheme 151

Remove right side instrument panel cover. Refer to Removal and Installation .

Disconnect connector at right vent temperature sensor -G151-.

Rotate right vent temperature sensor -1- 90° and remove from instrument panel.

Installing

Install in reverse order of removal.

CENTER VENT TEMPERATURE SENSOR - G191

Removing

Remove the cover on the instrument panel. Refer to Interior Trim .

Disconnect connector at center outlet temperature sensor -G191- -1-.

Rotate center outlet temperature sensor -2-, rotate 90° -in direction of arrow- and remove from instrument panel.

Installing

Install in reverse order of removal.

FOOTWELL VENT TEMPERATURE SENSOR - G192

Removing

Remove the knee airbag. Refer to Removal and Installation .

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Scheme 152

Disconnect connector at footwell outlet temperature sensor -G192- -1-.

Rotate footwell outlet temperature sensor 90° and remove from housing.

Installing

Install in reverse order of removal.

LEFT FOOTWELL VENT TEMPERATURE SENSOR -G261

Removing

Remove the knee airbag. Refer to Removal and Installation .

Remove the driver side footwell vent. Refer to DRIVER SIDE FOOTWELL VENT .

Disconnect connector at footwell outlet temperature sensor -1-.

Turn the footwell vent temperature sensor -2- 90° and remove it from housing.

Installing

Install in reverse order of removal.

RIGHT FOOTWELL VENT TEMPERATURE SENSOR -G262

Removing

Remove the front passenger footwell vent. Refer to FRONT PASSENGER SIDE FOOTWELL VENTS .

Scheme 153

Disconnect harness connector from right footwell vent temperature sensor -G262- -1-.

Rotate right footwell vent temperature sensor -2- 90° and remove it from housing.

Installing

Install in reverse order of removal.

COOLANT CIRCUIT COMPONENTS

1. «COOLANT PUMP IN FRONT OF HIGH VOLTAGE HEATER (PTC) -V509»(ref-480983-S24043063502012061900000) .
2. «TEMPERATURE SENSOR IN FRONT OF HIGH VOLTAGE HEATER (PTC) -G785»(ref-480983-S31479592392012061900000) .
3. «TEMPERATURE SENSOR AFTER HIGH VOLTAGE BATTERY HEAT EXCHANGER -G786»(ref-480983-S32547285932012061900000) .
4. «TEMPERATURE SENSOR AFTER HEAT EXCHANGER -G787»(ref-480983-S09658358802012061900000) .
5. «TEMPERATURE SENSOR AFTER ELECTRO-DRIVE DRIVE MOTOR -G788»(ref-480983-S39337320652012061900000) .
6. «TEMPERATURE SENSOR AFTER ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS -G789»(ref-480983-S27263512662012061900000) .
7. «HIGH VOLTAGE HEATER (PTC) -Z115»(ref-480983-S13750762772012061900000) .
8. «HEATER COOLANT SHUT-OFF VALVE -N279»(ref-480983-S18787777422012061900000) .
9. «HIGH VOLTAGE BATTERY COOLANT SHUT-OFF VALVE -N540»(ref-480983-S25317819492012061900000) .

CONTROL MODULE FOR HEAT AND A/C COMPONENTS

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. The Control Module for Heat and A/C Components is located under the driver seat.

Loosen the connectors -2-.

Remove the Control Module for Heat and A/C Components in the -direction of the arrow-.

Scheme 154

Installing

Install in reverse order of removal.

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

COOLANT PUMP IN FRONT OF ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS -V508

Special tools and workshop equipment required

Hose Clamps up to 25 mm -3094

Scheme 155

Spring Type Clip Pliers -VAS 5024A

Scheme 156

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Clamp the coolant hoses using the -3094-.

Loosen clamp -4-.

Scheme 157

Remove the coolant hoses from the coolant pump in front of electric drive power and control electronics -1-.

Disconnect the connectors -3- from the coolant pump in front of electric drive power and control electronics -1-.

Remove bolts -2- (8 +/- 0.8 Nm) and remove v -1-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit after the coolant pump in front of electric drive power and control electronics has been installed.

COOLANT PUMP IN FRONT OF HIGH VOLTAGE HEATER (PTC) -V509

Special tools and workshop equipment required

Hose Clamps up to 25 mm -3094

Spring Type Clip Pliers -VAS 5024AGolf

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Clamp the coolant hoses using the -3094-.

Loosen clamp -4-.

Scheme 158

Remove the coolant hoses from the coolant pump in front of high voltage heater (PTC) -1-.

Disconnect the connector -2- from the coolant pump in front of high voltage heater (PTC) -1-.

Remove bolts -3- (8 +/- 0.8 Nm) and remove coolant pump in front of high voltage heater (PTC) -1-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the coolant pump in front of high voltage heater (PTC) after it has been installed..

TEMPERATURE SENSOR IN FRONT OF HIGH VOLTAGE HEATER (PTC) -G785

Special tools and workshop equipment required

1. Drip Tray For Workshop Hoist -VAS6208
2. Hose Clamps up to 40 mm -3093
3. Compressed air gun, commercially available

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Remove the front noise insulation.

Disconnect the connector -1- from the temperature sensor in front of high voltage heater (PTC) -2-.

Scheme 159

Clamp the coolant hoses using the -3093-.

Note. Before removal, if necessary, release the pressure from the cooling system.

Remove the retaining clips -3-.

Remove temperature sensor in front of high voltage heater (PTC) -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor in front of high voltage heater (PTC) after it has been installed.

TEMPERATURE SENSOR AFTER HIGH VOLTAGE BATTERY HEAT EXCHANGER -G786

1. Drip Tray For Workshop Hoist -VAS6208
2. Hose Clamps up to 40 mm -3093
3. Compressed air gun, commercially available

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Remove charging unit 3.

Disconnect the connector -2- from the temperature sensor after high voltage battery heat exchanger -3-.

Scheme 160

Clamp the coolant hoses using the -3093-.

Note. Before removal, if necessary, release the pressure from the cooling system

Remove the retaining clips -1-.

Remove the temperature sensor after high voltage battery heat exchanger -3-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor after high voltage battery heat exchanger after it is installed..

TEMPERATURE SENSOR AFTER HEAT EXCHANGER -G787

1. Drip Tray For Workshop Hoist -VAS6208
2. Hose Clamps up to 40 mm -3093
3. Compressed air gun, commercially available

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Remove charging unit 3.

Disconnect the connector -2- from the temperature sensor after high voltage battery heat exchanger -3-.

Scheme 161

Clamp the coolant hoses using the -3093-.

Note. Before removal, if necessary, release the pressure from the cooling system

Remove the retaining clips -1-.

Remove temperature sensor after heat exchanger -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor after high voltage battery heat exchanger after it is installed..

TEMPERATURE SENSOR AFTER ELECTRO-DRIVE DRIVE MOTOR -G788

1. Drip Tray For Workshop Hoist -VAS6208
2. Hose Clamps up to 40 mm -3093
3. Compressed air gun, commercially available

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Disconnect the connectors -1- from the temperature sensor after electro-drive drive motor -G788- -2-.

Scheme 162

Clamp the coolant hoses using the -3093-.

Note. Before removal, if necessary, release the pressure from the cooling system

Remove the retaining clips -3-.

Remove temperature sensor after electro-drive drive motor -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor after high voltage battery heat exchanger after it is installed..

TEMPERATURE SENSOR AFTER ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS -G789

1. Drip Tray For Workshop Hoist -VAS6208
2. Hose Clamps up to 40 mm -3093
3. Compressed air gun, commercially available

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Disconnect the connector -1- from the temperature sensor after electric drive power and control electronics -2-.

Clamp the coolant hoses using the -3093-.

Note. Before removal, if necessary, release the pressure from the cooling system

Remove the retaining clips -3-.

Scheme 163

Remove temperature sensor after electric drive power and control electronics -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor after high voltage battery heat exchanger after it is installed..

HIGH VOLTAGE HEATER (PTC) -Z115

Special tools and workshop equipment required

Torque Wrench -V.A.G 1410

Scheme 164

Hose Camps up to 25 mm -3094

Spring Type Clip Pliers -VAS 5024A

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Remove the electro-drive drive motor.

Note. If coolant circuit is opened, it must be bled.. If drive motor is warm, coolant system is pressurized. Release pressure before repairs, if necessary.

Clamp coolant hoses using -3094-.

loosen spring clamps -1- and -4- and remove coolant hoses from the high voltage heater (PTC) -2-.

Scheme 165

Disconnect the connector -6- from the high voltage heater (PTC) -2-.

Remove the nut -3- and set the potential equalization cable aside.

Disconnect the high voltage cable -5- from the high voltage heater (PTC) -2-.

Remove bolts -7- and high voltage heater (PTC) -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the high voltage heater (PTC) after it has been installed.

HEATER COOLANT SHUT-OFF VALVE -N279

Special tools and workshop equipment required

Torque Wrench -V.A.G 1410

Hose Camps up to 25 mm -3094

Spring Type Clip Pliers -VAS 5024A

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. If coolant circuit is opened, it must be bled.. If drive motor is warm, coolant system is pressurized. Release pressure before repairs, if necessary.

Clamp the coolant hoses using the -3093-.

Disconnect the connector -1- from the heater coolant shut-off valve.

Scheme 166

Loosen the spring clamps -4- and remove the coolant hoses from the heater coolant shut-off valve -2-..

Remove bolts -3- (8 Nm) and heater coolant shut-off valve -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor after high voltage battery heat exchanger after it is installed..

HIGH VOLTAGE BATTERY COOLANT SHUT-OFF VALVE -N540

Special tools and workshop equipment required

Torque Wrench -V.A.G 1410

Hose Camps up to 25 mm -3094

Spring Type Clip Pliers -VAS 5024A

Removing

Read and follow the high voltage electrical system general warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Note. If coolant circuit is opened, it must be bled. If drive motor is warm, coolant system is pressurized. Release pressure before repairs, if necessary.

Clamp the coolant hoses using the -3093-.

Disconnect the connector -1- from the high voltage battery coolant shut-off valve.

Scheme 167

Loosen the spring clamps -4- and remove the coolant hoses from the high voltage battery coolant shut-off valve -2-.

Remove bolts -3- (8 Nm) and high voltage battery coolant shutoff valve -2-.

Installing

Installation is carried out in the reverse order while noting the following

Bleed the coolant circuit for the temperature sensor after high voltage battery heat exchanger after it is installed.

AUXILIARY COMPONENT BRACKET, A/C COMPRESSOR

Note. Removing the auxiliary component bracket in the Golf, from MY 2009, refer to [For transmission(s) 02E, 02Q] [For engine(s) CJAA] ACCESSORY BRACKET or [For transmission(s) 02E, 09G, 02Q] [For engine(s) CCTA, CBFA] ACCESSORY BRACKET .

EVAPORATOR HOUSING

Disassembling

Scheme 168

Remove the heater unit. Refer to HEATING AND A/C UNIT .

Remove the air distributor housing. Refer to AIR DISTRIBUTION HOUSING .

Remove the clamps -2- and the bolts -arrows- from the heater unit.

Remove the heater.

Assembling

Assemble in reverse order.